Reclosable dispenser package, reclosable outlet forming structure and method and apparatus for making same

ABSTRACT

An aperture forming structure, which when attached to or integrally formed in dispenser packages for flowable substances allows reclosure and single or multiple uses. The aperture forming structure includes a break away tip member of thermoformable plastic. The break away tip includes a hollow protrusion from a surface. The intersection of the hollow protrusion and the surface is a fault line. Rupturing of the fault line creates an aperture from which the contents of the dispenser package may exit. A cap may be integrally formed with the aperture forming structure and detached for protecting the hollow protrusion or for closing the aperture created when the fault line is ruptured. The aperture forming structure can be made by heating a relatively stiff substantially flat thermoformable sheet of and then stretching the sheet to create a first and a second hollow protrusion in a tiered configuration. A rupture line is placed at the intersection of the first and the second protrusions. The sheet may be attached to a pouch or containment member formed from a flexible sheet which contains any flowable substance.

[0001] This non-provisional application claims priority to U.S.Provisional Application Ser. No. 60/010,455, filed Jan. 23, 1996, andU.S. Provisional Application entitled “RECLOSABLE DISPENSER PACKAGE,RECLOSABLE OUTLET FORMING STRUCTURE AND METHOD AND APPARATUS FOR MAKINGSAME”, filed Jan. 3, 1997 by the same inventor of the instantnon-provisional application, both of which are herein incorporated byreference.

FIELD OF THE INVENTION

[0002] This invention relates to easy opening, self-contained, easy touse, single or multiple use dispenser packages capable of economical,high speed production, manufactured from a broad range of materials,many of which are recyclable. They may contain such products as syrups,cream, cheeses, salad dressings, shampoo, hand-cream, liquid detergents,motor oil, toothpaste pates, pet food and many other products. Itadditionally relates to a package which has the capability of dispensingthe contained product, e.g., mouthwash, cough syrup, confections,alcoholic beverages, etc., directly into the mouth of the user, andwhich also includes a reclosure cap member formed as an integral part ofthe package and which preferably is tethered to the package by a tetheralso formed integrally with the package. It will also be seen that theeasy opening feature together with the reclosure cap and tether may beformed independently and sealed or adhered to the surface of manypackages such as bags, milk containers, pouches, pillow packages(sachets), etc. to make for very efficient low cost dispensing packagesor squeeze bags. These squeeze bag type packages could dispense foodpastes such as pet food, cremes, grease, yogurt, certain types of dough,cake frosting and could be made of everything from treated, coatedpaperboard plastic films, foils, laminates or coextrusions of thesematerials. The easy opening means of this application in its preferredembodiment is comprised of a drum-like protrusion from which a secondaryfrusto conical protrusion extends to create a tip which is encircled atits base by a fault line. To create the aperture this tip is broken awayby applying light lateral finger pressure. In order to protect thisbreakaway tip during shipment or for reclosing the aperture, a tetheredcap is also formed adjacent to the double protrusion. The tetherfunctions not only to hold the cap, thereby preventing the cap frombeing lost, but also to hold the cap [on the tip] in place by actinglike a spring.

[0003] In an alternate aperture forming system the initial drum likeprotrusion has, instead of a frusto-conical breakaway tip, a fault linepattern defined in its top surface, so designed as to rupture to createan outlet of various required shapes when a puncturing tool/plug ispressed into said fault line pattern. Such puncturing tool/plug may beformed instead of a cap and may be tethered or the cap may be doubleended with a cap formation on one end and the puncturing tool/plugformation on the other. It will also be seen that a cap containing aprotruding member formed within the cap similar to the style of a flowerwould perform as a central punch when the cap is pressed over the drumshaped protrusion. It will further be seen that in certain instanceswhere a metal foil liner is required for a flowable product such as analcoholic drink the drum shaped protrusion may be replaced by amoundlike protrusion with a central fault line pattern. The reason forsuch a moundlike shape instead of the drum shape is to prevent thestretching of the foil beyond its elastic limit at surface intersectionsin which case it would rupture during formation. Said pattern able to bepunched open by a formed puncturing tool/plug said puncturing tool/plugmay be thermoformed and tethered to the unit or may be independentlymade and the tether may have a formed ring at its free end into whichthe puncturing tool plug may be seated.

[0004] This invention also relates to a method and apparatus formanufacturing the aforesaid formation and packaging, reliably at highspeed, in many cases from fully recyclable material, so as to permitsuch packages to be produced at low cost and, in many cases, recyclable.Additionally the packages may use less plastic material than most otherpreviously known portion packages leading to source reduction andenvironmental benefits even when non-recyclable materials are used.

BACKGROUND OF THE INVENTION

[0005] Various attempts have been made to provide a dispenser package inwhich a product may be packaged in the quantity normally required forsingle or multiple uses, and from which the contained product may bedispensed.

[0006] One type of such dispenser packages is a pillow pouch or sachet,typically made of relatively thin plastics and foils or combinations oflaminated plastics and foils. These packages are most frequentlyencountered as containers for catsup, mustard, other condiments,homecare preparations such as hair conditioners, dyes and cremes, etc.Although this type of package is universally used, it is alsouniversally disliked by the consumer. In order to access the contents,the pouch must be held in one hand while a tearing motion and force areapplied by the other hand. Creating the initial tear to break thepackages seal is often very difficult, often requiring the assistance ofthe user's teeth. Moreover, once the initial tear is created, thelaminated foil and/or plastic material not only often tears in anuncontrolled fashion, but the holding pressure exerted by one of theuser's hands often forces the contents out of the envelope not onlybefore the user is ready to apply the contents, but even before thetearing motion is complete. Opening these packages leads to frayedtempers, broken fingernails, and chipped teeth, as well as otherproblems. The user must also use both hands to open the container. Inthe case of invalids, arthritis sufferers and other handicapped people,opening these packages is virtually impossible. Yet another problemassociated with these prior packages is the impossibility of efficientreclosure, thereby precluding multiple use of the package, withconsequent waste of the unused contents. Further disadvantages includethe sachet's inability to function effectively with low viscosityproducts such as coffee cream, mouthwash or alcoholic beverages, due tothe inability of the torn opening to control the direction of flow ofsuch liquids from the package. These packages also are generally totallyunrecyclable, and therefore become environmental pollutants. Asabove-mentioned however, should continued use of these sachets bepreferred, then the easy opening feature of this application may bereadily and economically adhered to the sachet to make for an easyopening, reclosable, high-barrier package.

[0007] Another dispenser package is the peel-top cup used for butter,margarine, syrup, sauces, salad dressing, and other similar products.This type of package requires good eyesight and manual dexterity. Suchpackages are often used as coffee creamers and have many disadvantages,including difficulty in peeling off the top in order to open, as well asdifficulty in pouring, accidental spilling, and the inability to bereclosed so as to preclude more than a single use. Again the inventionsdescribed herein can be adhered or integrally formed into these packagesto make them easy opening and reclosable. Yet another type of dispenserpackage is the unsealed corrugated paper package used for salt and/orpepper, which upon bending along an interrupted line cut through thecorrugations forms an opening through which the salt or other materialcontained in the package may flow. These packages only dispense dry,solid flowables with the assistance of gravity, and cannot be used tocontain, no less dispense, “wet” or liquid flowable materials. Thepackage of this invention can contain and readily dispense both liquidsand dry granular products.

[0008] Small, very expensive, metal capped bottles are used foralcoholic drinks and are either poured or consumed directly from thebottle. These bottles may be reclosed, but often are sized for a singledrink so they do not have to be reclosed. The instant package can beused for alcoholic beverages at a fraction of the cost of the bottles.

[0009] Everyone is familiar with the ubiquitous gable top milk cartonand everyone is familiar with the varying degrees of difficulty inopening them. These range from fingernail breaking to just plainunopenable without a knife or other tool.

[0010] They never truly reclose and at best are messy and uncleanlooking. In the U.S. there has been a move toward mounting a screw-oncap combination comprising a threaded nozzle member which is sealed ontoone of the slanted gables of the carton and the other is an unattachedscrew-on cap. This little injection molded duo is costly to make and toinstall, possibly on the order of 3 to 5 cents and is commonly used onlarge gable top juice containers in the half gallon size. These areexpensive, high profit items selling for about three dollars each andcan bear the extra tariff for the screw-on outlets. There are howeverbillions of these gable top units sold annually for milk and cream invarying sizes from half-pints to half gallons. Producers however arereluctant to increase carton cost significantly and the public continuesto use difficult to open cartons.

[0011] The instant invention makes available a sealed and tamper evidentoutlet with a tethered cap, both formed in a single, small plastic unitwhich can be readily sealed or adhesively attached to the gable over asmall pre-made hole. It is ultra low cost and may be made ofpolypropylene, high density polyethylene, PVC. Polyester etc. utilizingmaterial costing small fractions of a cent. It will be seen that the capserves a double purpose. It enables the outlet to be reclosed afteropening and of equal importance, since the cap is in place over thebreakaway tip during shipment it protects the tip from beingaccidentally hit or subjected to any forces which may open the outlet.

[0012] It may be seen that the lower drum-like formation beneath thebreakaway tip may be elongated so that when the tip is broken away, anelongated nozzle remains which would allow the flowable substance to beingested directly from the container or as in the case of motor oil,being poured directly into the engine oil inlet. Another disadvantagecurrently experienced with dispensing packages is the closing of theoutlet opening. Closing the outlet opening of tubes is presentlyaccomplished by means of an injection molded screw-on cap which normallyincludes a compressible gasketing material. The end of the tube requiresa mating thread to match the cap. Both the separately molded gasketedcap and the threaded tube result in increased manufacturing costs.Additionally, the cap, as often as not, is dropped and/or lost while itis being threaded on or off. Furthermore, there has been a growing trendto manufacture such tubes at still greater cost by providing hinged capswith a flat end surface which permits the tube to stand upright. Thus,the cap members currently in use have the disadvantage that they tend toincrease the overall cost of manufacture of the dispensing package.

OBJECTS OF THE INVENTION

[0013] It is therefore an object of this invention to provide a new andimproved means of creating an aperture in a thermoformable plasticmaterial as well as an integrally formed cap and tether where necessary.

[0014] A further object is to form independently such aperture creatingmeans with or without a cap and/or tether for adhesion to other forms ofpreviously difficult to open or non-reclosable packaging.

[0015] Another object of this invention is to provide new and improveddispenser packages.

[0016] Another object of this invention is to provide a new and improvedaperture-forming structure for a dispenser package which allows the userto easily and controllably dispense the contents of the package directlyto the user's mouth or in a directionally controlled manner, as desired.

[0017] Another object of this invention is to provide a new and improvedaperture-forming structure for a dispenser package which opens easilyand reliably and yet which can be manufactured economically and at highspeed.

[0018] Another object of this invention is to provide a new and improvedreclosable dispenser package so that the contents thereof may bedispensed in consecutive uses and the outlet opening reclosed betweenuses.

[0019] A further object of this invention is to provide a new andimproved reclosable package with an attached cap member formed from thesame plastic film which cap member may be thereafter placed over theunopened aperture forming means to protect it and/or to reclose thepackage after opening.

[0020] Another object of this invention is to provide a new and improvedreclosable package and removable cap member which may be formed as anintegral unit and where the cap member is attached to an integrally madetether and remains attached to the package and which may be placed overthe unopened aperture forming means to protect it from changes oraccidental opening during shipping and handling.

[0021] Another object of this invention is to provide a new and improvedreclosable package and tethered cap member which may be formed as anintegral unit from a thermoformable material.

[0022] Another object of this invention is to provide a new and improvedreclosable package and tethered cap member which may be formed as anintegral unit from a thermoformable plastic material that is recyclable.

[0023] Another object of this invention is to provide a new and improveddispenser package and cap member wherein the cap member has anopen-ended top of predetermined shape so that, upon placing the cap overthe aperture of the package the contents may be dispensed in such shapedstream.

[0024] Another object of this invention is to provide a new and improveddispenser package and cap member wherein the cap member includes autensil device such as tiny protrusions or a flattened surface structureso that the cap member may function as a tool to brush, spread, orotherwise handle the contents dispensed from the package.

[0025] Another object of the invention is to replace the cap member witha dual function punch/plug member capable of punching through a toughpre-scored formation to create an aperture and to further act as a plugto close said aperture.

[0026] A still further object of this invention is to provide a new andimproved method of making a dispenser package embodying the aforesaidfeatures.

[0027] Another object of this invention is to provide a new and improvedmethod of thermoforming a dispenser package from a recyclable plasticmaterial at high speed and yet provide a finished package which may beeasily and reliably opened by the user.

[0028] Another object of this invention is to provide a new and improvedapparatus for forming an aperture-forming structure for a dispenserpackage.

[0029] Another object of this invention is to provide a new and improvedapparatus for forming a nozzle-like aperture structure in a dispenserpackage so that, upon opening, the contents of the package may bedispensed in a directionally controllable manner.

[0030] Another object of this invention is to provide a new and improvedself-centering and self-aligning punch and die apparatus adapted toaccurately and reliably form a thermoformable material into a hollowtip-like configuration having a peripherally extending fault line so asto permit the tip to be readily broken away by the user to form anaperture opening through which the contents of the package may bedispensed.

[0031] The foregoing specific objects and advantages of the inventionare illustrative of those which can be achieved by the present inventionand are not intended to be exhaustive or limiting of the possibleadvantages which may be realized. Thus, these and other objects andadvantages of the invention will be apparent from the description hereinor can be learned from practicing the invention, both as embodied hereinor as modified in view of any variations which may be apparent to theseof ordinary skill in the art, the same being realized and attained bymeans of the parts, constructions and instrumentations, and combinationsthereof, as well as in the steps and processes pointed out in theappended claims. The present invention resides in the novel parts,constructions, arrangements, combinations, steps and processes, andimprovements, herein shown and described.

SUMMARY OF THE INVENTION

[0032] Briefly described this invention is directed to a new reclosableaperture forming means which may be formed with an integrally formed capmember which may be tethered to said aperture forming means to create aunit which may be independently formed and adhesively or sealinglyattached to a container wall or surface over a hole in said containerwall to create an easy opening, reclosable, when necessary, dispensingpackage. Said reclosable aperture forming means embodying an integral,hollow protrusion member preferably comprised of two stages, a drumshaped base from which extends a generally conical or frusto-conicaltip, said tip member having a fault line encircling it at its juncturewith the flat top surface of the first drumlike formation which may bereadily broken off to form an opening through which the contents of thepackage may be dispensed in a directionally controllable stream. Afterthe tip of the protrusion member is broken off by applying light lateralfinger pressure, the desired quantity of the contents may thereafter beexpelled through the opened nozzle-like outlet by gentle hand squeezingof the package.

[0033] In a second embodiment the entire reclosable aperture formingmeans may be integrally formed into what will become an easy to usereclosable dispensing package. In this second embodiment a generallyrelatively flexible, compressible pouch or container member is sealablyattached to a cover member forming the top or lid of the package. Thecover member includes the new reclosable aperture forming means andtethered cap member as described above and similarly used.

[0034] In another desirable embodiment the pouch or container member hasthe integral hollow protrusion and tethered cap member thermoformed intothe underside of its relatively stiff rim. The advantage of this versionbeing that the cover member then becomes a relatively thin skinlikemember which is very easy to print and less expensive than the formedupper cover member.

[0035] The aforesaid cap member which is initially formed with thepackage as an integral unit is preferably formed along one peripheraledge of either the cover member forming the top or lid of the packagerelatively closely adjacent to the breakaway protrusion member or on theunderside of the rim. A cut line may create a tether member whichpermits the cap member to be mechanically removed by the user from itsmolded position in production and placed over the opened nozzle-likeaperture forming means so as to protect the breakaway tip duringshipping and handling, while remaining tethered to the package. As alsopreferably embodied, the aforesaid cap member permits the end user ofthe package to readily open or reclose the package after each use.

[0036] In other alternative embodiments of the dispenser package of thepresent invention:

[0037] (i) the breakaway protrusion member forming the aperture in thepackage may be broken off at the surface of the cover member forming thetop or lid of the package, thereby eliminating the nozzle-like outletconfiguration in those applications where the contents of the packagedon't require nozzle formation;

[0038] (ii) the cap member may be formed with miniature protrusions toact like a brush, or may have some other desired shape to perform someother desired tool function for use in handling the contents dispensedfrom the package, such as by brushing or spreading;

[0039] (iii) if reclosing the package is not required, the cap membermay be open-ended having a predetermined shape such that, upon placingthe cap member over the nozzle-like aperture of the package, thecontents may be dispensed in such shaped stream;

[0040] (iv) the cap member may be provided with an internal central plugdimensioned to mate with the opening formed in the dispenser package tothereby serve as a plug to further ensure sealing of the opening afterremoval of the breakaway protrusion member; and

[0041] (v) the breakaway protrusion and tethered cap members may beformed in a portion of the cover member which extends beyond one end ofthe compressible pouch member at a predetermined angle and communicateswith the product contained in the pouch by means of a shallow neck orchannel, thereby facilitating application of the contents of the packageonto a surface, such as, e.g., toothpaste onto a toothbrush or glue ontoa break line. Alternatively, the breakaway protrusion member may beformed in the cover member directly over the pouch portion with the capformed at an adjacent small flat area. This method yields a somewhatlarger pouch volume while using the same total amount of material.

[0042] It will be understood that the foregoing preferred embodiments ofthe dispenser package of the present invention may be thermoformed froma wide variety of plastic materials, including, e.g., PP (polypropylene)Barex, HDPE (high density polyethylene), HIPS (high impact polystyrene)and foamed HIPS, as well as various laminations and/or coextrusions ofthe aforesaid materials and other plastic materials, including, e.g.,PP/EVOH (ethylene vinyl alcohol)/PP; Barex/PP; Barex/EVOH/PP; PET(polyethylene tetrafluoride)/LLDPE (linear low density polyethylene);PET/EVOH/LLDPE; PVC (polyvinylchloride)/LLDPE; NY (nylon)/LLDPE; andNY/EVOH/LLDPE. Alternatively, the aperture forming means and thedispenser packages of the present invention may be formed by injectionmolding.

[0043] It also will be understood that the foregoing preferredembodiments of the dispenser packages of the present invention may bemanufactured in a wide variety of sizes, as desired, although thepreferred size range is from about 2 ml capacity to about 4 fluid ouncecapacity. Similarly, the aforesaid package may be manufactured in a widerange of dimensions. A typical size for a package containing 30 ml or 1fluid ounce of material is on the order of about 1 inch deep by about 1inch wide by about 3 to 4 inches long, which fits comfortably in thepalm of the hand of most users. Furthermore, the independent formationsof aperture forming means and the tethered caps may be applied to a verywide range of packaged from single use sizes to half gallons.

[0044] Briefly described, as preferably embodied, the apparatus of thepresent invention forming the preferred aperture-forming protrusionmember in the cover member of the dispenser package includes a two-stagepunch member which advances to engage and clamp a thermoformablematerial against a self-centering and self-aligning hollow anvil member.The first punch member advances to initially form a hollow, drum-shapedprotrusion in a specific heated area of the thermoformable material.Thereafter, a second punch member preferably located within, andmoveable relative to, the first punch member continues to advanceforward. The second punch member includes a first generallyfrusto-conically shaped surface adapted to form a substantiallycylindrical or frusto-conically shaped hollow tip member extending fromthe drum-like protrusion formed by the first punch member. At the momentformation of the hollow tip member is completed, the forward advancementof the second punch brings a second shallow conical surface intocooperating engagement with the peripheral edge or rim defining thehollow portion of the anvil member to thereby compress the wall of theformed hollow tip about a peripheral portion thereof to create aweakened fault line in the hollow tip protrusion member. As herepreferably embodied, the aforesaid punch and anvil members create afault line at the base of the aforesaid hollow tip protrusion memberwhich extends continuously about the periphery thereof.

[0045] In an alternative embodiment of the apparatus of the presentinvention, the heated sheet of thermoformable material is clampedagainst the anvil member and a single stage punch member having agenerally frusto-conically shaped forward end portion is thereafteradvanced to form the aforesaid hollow, substantially cylindrical orfrusto-conically shaped tip member. At the moment formation of thehollow tip member is completed, the rim of the anvil member compressesthe wall of the hollow tip member about the periphery thereof to createa weakened fault line. It will be seen that the heated thermoformablefilm (material) may be clamped against a relatively thin plate spacedaway from the anvil which contains an accurately aligned hole centeredon the aperture of the anvil member. In this embodiment, between thepunch and anvil the film will be formed into a conical member as thepunch is advanced through the plate and said conical member will then befurther formed until it contacts the peripheral edge or rim at theopening of the aperture in the anvil. This alternate apparatus creates afault line banding or girdling the formed conically-shaped tip member ata predetermined point between its base and its apex.

[0046] It will be appreciated by those skilled in the art that theforegoing various brief descriptions and the following detaileddescription are exemplary and explanatory of the present invention, butare not intended to be restrictive thereof or limiting of the advantageswhich can be achieved by the invention or various combinations thereof.The accompanying drawings, referred to herein and constituting in parthereof, illustrate preferred embodiments of the invention and, togetherwith the detailed description, serve to explain the principles of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0047]FIG. 1 is a side elevation view of a dispenser package constructedin accordance with the present invention with an integrally formed capmember;

[0048]FIG. 2 is a top plan view of the dispenser package of FIG. 1;

[0049]FIG. 2a is a perspective view of a dispenser package constructedin accordance with the present invention with an integrally formed capmember on the underside of the containment members rim and their skinlike unformed cover member;

[0050]FIG. 3 is an end view of the dispenser package of FIG. 1;

[0051]FIG. 3a is an end view of the dispenser package of FIG. 2a showingan unformed very thin flexible cover member;

[0052]FIG. 4 is a side view in elevation, partly sectional, of anapparatus constructed in accordance with the present invention forforming the breakaway tip and nozzle protrusion members in a heatedsheet of thermoplastic material;

[0053]FIG. 5 is an enlarged sectional view, partly in elevation, of thefirst and second punch members and the self-aligning hollow anvil memberillustrated in FIG. 4, this view illustrating formation of the firstprotrusion member in the thermoplastic sheet material;

[0054]FIG. 6 is an enlarged view similar to FIG. 5, illustratingformation of the second protrusion member in the thermoplastic sheetmaterial;

[0055]FIG. 7 is an enlarged view of FIG. 6, illustrating formation ofthe peripherally extending weakened fault line at the base of the secondprotrusion member;

[0056]FIG. 7a an enlarged side plan view of first and second protrusionmembers according to one embodiment of the present invention;

[0057]FIG. 7b is an enlarged side plan view of first and secondprotrusion members according to one embodiment of the present invention;

[0058]FIG. 8 is an isometric view of the dispensing package of FIG. 1;

[0059]FIG. 9 is an enlarged isometric view of the dispensing package ofFIG. 8, illustrating the cap member removed from its molded position andplaced over the breakaway tip protrusion member;

[0060]FIG. 10 is a schematic illustration showing the use of a hollowpunch member for forming a central sealing plug member in the cap memberillustrated in the preceding drawings;

[0061]FIG. 11 is an isometric view of a cap member formed with a centralplug from the apparatus of FIG. 10;

[0062]FIG. 12 is an enlarged cross-sectional view, partly in elevation,illustrating an alternative embodiment of the punch and anvil apparatusof the present invention, wherein a single punch member forms a hollowfrusto-conical protrusion in the surface of the cover member for adispenser package and the anvil member compresses the wall of the tip toform a peripherally extending fault line on the surface of theprotruding tip;

[0063]FIG. 12a is an enlarged cross-sectional view, partly in elevation,illustrating an alternative embodiment of the punch and anvil apparatusof the present invention, wherein a single punch member forms a hollowfrusto-conical protrusion having a right-cylindrical base in the surfaceof the cover member for a dispenser package and the anvil membercompresses the wall of the tip to form a peripherally extending faultline on the surface of the protruding tip;

[0064]FIG. 12b is an enlarged cross-sectional view, partly in elevation,illustrating an alternative embodiment of the punch and anvil apparatusof the present invention, wherein a single punch member having aspherical tip forms a hollow mound protrusion in the surface of thecover member for a dispenser package and the anvil member compresses thewall of the tip to form a peripherally extending fault line on thesurface of the mound;

[0065]FIG. 13 is a schematic elevation view of the breakaway tip formedby the punch and anvil members illustrated in FIG. 12;

[0066]FIG. 13a is a schematic elevation view of the breakaway tip formedby the punch and anvil members illustrated in FIG. 12a;

[0067]FIG. 14 is a top plan view of another embodiment of a dispenserpackage constructed in accordance with the present invention, whereinthe breakaway tip and cap member are formed in a lateral extension ofthe cover member and the breakaway tip member communicates with thecontainment pouch through a shallow channel member;

[0068]FIG. 15 is a side view of the embodiment illustrated in FIG. 14;

[0069]FIG. 16 is an end view of the embodiment illustrated in FIG. 14;

[0070]FIG. 17 is a side view of the embodiment of the inventionillustrated in FIG. 14, wherein the lateral extension of the covermember also extends angularly downwardly;

[0071]FIG. 18 is a schematic view of an alternate embodiment of the capmember, formed with bristles or nubs on its outer surface;

[0072]FIG. 19 is a schematic view of another alternate embodiment of thecap member, formed with a flattened spreader tool utensil on its outersurface;

[0073]FIGS. 20a-d are partial end views of still other alternateembodiments of the cap member of the present invention, each viewillustrating an open-ended cap member;

[0074]FIG. 21a is a top plan view of a reclosable outlet apertureforming structure which can be applied to various forms of containers inaccordance with an alternate embodiment of the present invention;

[0075]FIG. 21b is a side view of the reclosable outlet aperture formingstructure shown in FIG. 21a;

[0076]FIG. 22a is a perspective view of the reclosable outlet apertureforming structure of FIGS. 21a-b, as applied to a milk carton, in whichthe cap is placed over the outlet;

[0077]FIG. 22b is a perspective view of the reclosable outlet apertureforming structure of FIGS. 21a-b, as applied to a milk carton, in whichthe cap is removed from the outlet so as to allow removal of thebreakaway outlet tip;

[0078]FIG. 22c is a perspective view of the reclosable outlet apertureforming structure of FIGS. 21a-b, as applied to a milk carton, in whichthe breakaway tip is removed from the outlet to form an openingtherethrough;

[0079]FIG. 22d is a perspective view of the milk carton of FIGS. 22a-c,in which the breakaway tip is removed from the outlet to form an openingthrough which milk is being poured;

[0080]FIG. 23 is a side view of a low profile breakaway tip inaccordance with another embodiment of the present invention;

[0081]FIG. 23a is a side view of a low profile breakaway tip inaccordance with another embodiment of the present invention;

[0082]FIG. 24 is a top view of the low profile breakaway tip of FIG. 23;

[0083]FIG. 24a is a top view of the low profile breakaway tip of FIG.23a;

[0084]FIG. 25 is a perspective view of the low profile breakaway tip ofFIG. 23 with the removed breakaway tip shown in phantom;

[0085]FIG. 26 is a side view of a cap for use with the low profilebreakaway tip of FIG. 23;

[0086]FIG. 27 is a side view of a another embodiment of the presentinvention which utilizes a twist-lock or twist-threading arrangement tosecure the cap to the base formation;

[0087]FIG. 28a is a perspective view of another embodiment of thepresent invention in which a tethered plug is used to open and close apre-scored surface;

[0088]FIG. 28b is a perspective view of the embodiment of FIG. 29a inwhich the pre-scored surface has been opened;

[0089]FIG. 28c is a perspective view of the embodiment of FIG. 28a inwhich the plug has been placed in the outlet hole, thereby opening thehole along the pre-scored surface and/or plugging the hole;

[0090]FIGS. 29a-d are top views of the outlet of the embodiment of FIG.28a depicting various types of scored surfaces formed in the outlet; and

[0091]FIGS. 30a-d are side views of the scored surfaces shown in FIGS.29a-d, in which each of the scored surfaces haves been penetrated tocreate an opening therethrough and a flap descending from the surface;

[0092]FIG. 31 is a partially elevated side view of an outlet formingstructure according to an alternative embodiment of the presentinvention, having a punch/plug and a scored mount, as applied to a milkcarton;

[0093]FIG. 32 is a top plan view of the outlet forming structure of FIG.31;

[0094]FIG. 33 is a side plan view of the outlet forming structure ofFIGS. 31 and 32;

[0095]FIG. 34 is an enlarged elevated view of the outlet formingstructure of FIGS. 31-33;

[0096]FIG. 35 is an enlarged side plan view of the outlet formingstructure of FIGS. 31-34 showing the mound as punctured by thepunch/plug;

[0097]FIG. 36 is an enlarged side plan view of the mound of FIGS. 31-35;

[0098]FIG. 37 is a side plan view of an alternative embodiment of thepresent invention in which an outlet forming structure, having abreakaway tip and cap, is applied to a foil package;

[0099]FIG. 38 is an enlarged side elevational view of the outlet formingstructure of FIG. 37;

[0100]FIG. 39 is an elevated plan view of an alternative embodiment ofthe present invention as applied to a foil package;

[0101]FIG. 37a is a side plan view of an alternative embodiment of thepresent invention in which an outlet forming structure is applied to afoil package;

[0102]FIG. 38a is a front plan view of the outlet forming structure ofFIG. 37a;

[0103]FIG. 39a is an elevated plan view of the outlet forming structureof FIGS. 37a and 38 a;

[0104]FIG. 40 is a partial elevational view of an outlet formingstructure according to another alternative embodiment of the presentinvention, having a snap-in auxiliary punch/plug/cap and protrusionmember, that is manufactured by a pick-and-place method;

[0105]FIG. 40a is an enlarged side plan view of the outlet formingstructure of FIG. 40 showing the punch/plug/cap puncturing theprotrusion member;

[0106]FIG. 41 is a top plan view of an alternative embodiment, whereinthe outlet forming structures are formed from a single thermoplastic webin a mating arrangement;

[0107]FIG. 42 is a side plan view of an alternative embodiment of thepresent invention in which the reclosable container is provided with ascored protrusion and a dual purpose tethered punch/cap;

[0108]FIG. 43 is a top plan view of the reclosable container of FIG. 42;

[0109]FIG. 44 is a top plan view of the reclosable container of FIGS. 42and 43, wherein the tethered punch/cap is securely fastened over thescored protrusion;

[0110]FIG. 45 is an elevated plan view of an outlet forming structureaccording to one embodiment of the present invention;

[0111]FIGS. 46a-c are side plan views of a container for use with anoutlet forming structure according to the present invention;

[0112]FIG. 47 is an elevated plan view of the container of FIGS. 46a-cwith the outlet forming structure of FIG. 45 mounted thereon;

[0113]FIG. 48 is a top plan view of a container according to anembodiment of the present invention;

[0114]FIG. 49 is a side plan view of the container of FIG. 49;

[0115]FIG. 50 is a side plan view of the container of FIGS. 48 and 49 ina closed position;

[0116]FIG. 51 is a side perspective view of the container of FIGS.48-50;

[0117]FIG. 52 is a side elevational view of a container according to anembodiment of the present invention;

[0118]FIG. 53 is an enlarged side plan view of the outlet formingstructure of FIG. 52; and

[0119]FIG. 54 is a top plan view of a section of a web of thermoformablematerial having a series of outlet forming structures formed therein.

DETAILED DESCRIPTION OF VARIOUS PREFERRED EMBODIMENTS

[0120] Referring now more particularly to FIGS. 1-4 and 9 of theaccompanying drawings, there is illustrated a dispensing packageindicated generally at 10 according to the present invention. Thepackage 10 can be used for single or multiple uses and can be reclosedfor further use.

[0121] As illustrated in FIGS. 1 and 4, the package 10 includes a covermember 11 formed from a flexible but relatively stiff generally flatsheet 12 of a thermoformable plastic material most suitable to theproduct contained and the protection that the contained productrequires.

[0122] Materials such as high-impact polystyrene (HIPS), high densitypolyethylene (HDPE) polyester, HDPE/EVOH (high densitypolyethylene/ethylene vinyl alcohol), Barex, polypropylene, etc. may beused. HIPS, HDPE, and HPDE/EVOH are each low cost and can be recycled.HDPE/EVOH creates a superior O₂ barrier.

[0123] As will be understood by those skilled in the art, whereasplastics of similar material may be heat-sealed or bonded together, heatsealing different plastics together requires an adhesive layer.Preferably, linear low density polyethylene (LLDPE) is used as such alayer. Thus, multi-layered plastics formed by coextrusion may be sealedtogether to form sheet 12 having sealant/barrier 14 of the presentinvention.

[0124] Also suitably bonded to one face of bonded sheet 12, 14 is aflexible sheet 18 forming at least one pouch chamber 22 adjacent oneface of the relatively stiff sheet 12 or bonded sheet 12, 14 forcontaining a preferably flowable substance, e.g. a dry powdered orgranulated material or a liquid material of any suitable viscositycapable of flowing under light to moderate hand pressure.

[0125] Advantageously, and as here preferably embodied, the layer of asuitable sealant/vapor impervious barrier material 14 is suitablyintegrally bonded to sheet 12 on the inner surface 16 which facesflexible sheet 18. Flexible sheet 18, advantageously formed byconventional means, such as vacuum forming, pressure forming, mechanicalforming or combinations thereof, is likewise suitably integrally bondedto either inner surface 16 or sealant/barrier 14 of sheet 12, as thecase may be.

[0126] The bonds between substantially flat relatively stiff sheet 12,sealant/barrier material 14 and flexible sheet 18 also may be formed byconventional means known to persons of ordinary skill in the packagingart, such as welding, heat sealing, or adhesive or cohesive bonding. Itwill be understood that the particular bonding method selected dependsupon the particular properties of the materials used and the flowablesubstance(s) to be contained in the package.

[0127] Advantageously, and as preferably embodied, sheet 12 ispreferably made of polypropylene (PP), Barex, high impact polystyrene(HIPS) or high-density polyethylene (HDPE), but when combined withbarrier 14 may be made of polystyrene, polyester, EVOH (ethylene vinylalcohol), polyvinyl chloride (PVC), polyethylene tetrafluoride (PET) ornylon, or a copolymer thereof, and barrier 14 is made of a suitablesealant/vapor impervious barrier material, preferably comprising saranand foil laminate, or comprising a laminate of foil and vinyl, or foilalone, depending on the nature of the contents to be contained.

[0128] A particularly tough high barrier construction comprises saranlaminated on each side with polyethylene (sold by Dow Chemical Co. underthe name “Saranex”) as barrier sheet 14, in turn laminated ontopolystyrene or polyester, forming the flexible but relatively stiffsheet 12. The thickness of sheet 12 varies according to factors, such asthe properties of the materials used, the flowable substance contained,and the intended usage. A generally utilized range is 4-12 mils(0.004-0.012″). As previously noted, sheet 12 preferably is somewhatflexible, although more rigid than the material 18 forming pouch 22, andpreferably is stiffened by raised portion 11 a formed in cover 11 in thepreferred construction of package 10.

[0129] It will be understood by those of ordinary skill in the art thatthe bonds formed between materials 12, 14 and 18 can be obtained by theconventional means previously described, again depending on the natureof the flowable substance being contained.

[0130] It will be seen from the foregoing that the structure of FIGS. 1and 2 forms an enclosed pouch or chamber 22 between the flexible sheet18 and the relatively stiff member 12, 14 in which a preferably flowablesubstance is contained and from which the contained substance isdispensed.

[0131] In accordance with the present invention as preferably embodied,the relatively stiff generally flat sheet 12 forming cover 11 includesan aperture-forming protrusion structure 30 which includes a neck member32 and a breakaway tip member 34 so that, upon removal of tip 34, neck32 forms a nozzle-like aperture in package 10 through which the contentsmay be dispensed in a directionally controllable manner.

[0132] Neck and tip protrusions 32, 34 preferably are substantiallyhollow, substantially cylindrical and tip 34 preferably is substantiallycylindrical or frusto-conical. In the preferred embodiment as shown inthe plan view of FIG. 3, the aperture-forming protrusion structure 30 islocated in cover 11 directly over pouch 22 so that, when opened, nozzleaperture 32 communicates directly with the contents of pouch 22.

[0133] In accordance with the present invention, as preferably embodied,dispenser package 10 includes a cap member 110 formed as an integralpart of cover 11. Advantageously, cap member 110 is removable from cover11 along a line.

[0134] It will be seen that the cap 110 protects the breakaway tipstructure 30 from inadvertently breaking off during shipping andhandling prior to use, as well as providing a means to reclose thepackage after opening, i.e., after the protrusion tip member 34 isbroken off. Thus, cap 110 protects the remaining contents of the packageafter each use, permitting multiple uses. The advantage of the tetheredembodiment of the invention is that it costs practically nothing, actsas a side pressure spring to maintain the cap on the neck 32 at theopening, acts as a grasping member to assist removal of the cap for eachsubsequent use, and prevents loss of the cap before the contents of thepackage have been fully dispensed and the package is ready to bedisposed of. Further details of the cap are explained below.

[0135] In practically all cases, however, it is believed preferable toprovide the two-stage breakaway tip configuration since the firstprojecting cylindrical formation 32 acts as a nozzle yieldingdirectionally controllable product dispensation, after the tip, i.e.,second protrusion 34, is broken off. Low and medium viscosity flowableproducts tend to squirt “side-ways” or spurt in non-controllabledirections, when passing through an aperture formed in the plane of thecover member. Furthermore, elevating the breakaway tip from the surfaceof the cover member greatly enhances its ease of use with no practicalincrease in manufacturing cost.

[0136] In use, as here preferably embodied, package 10 preferably ispositioned so that pouch or chamber 22 rests in the palm of the handwith the thumb resting on the cover 11. The thumb or finger of theholding hand, or the user's other hand, if desired, may then be used toapply a light finger pressure against the side of protrusion tip 34,i.e., the breakaway tip, thereby causing tip 34 to break off, leaving anopen neck or nozzle-like aperture 32.

[0137] Once tip 34 is removed and the package thereby opened, thecontents of the package 10 may be expelled. This method of use dependson the type of substance contained in the package and where the userwould like to place the contents. For example, if the package containstoothpaste, the open nozzle 32 preferably would be placed over a toothbrush, whereupon gentle squeezing of the package 10 will force thetoothpaste onto the toothbrush. If the contents of the package areintended to be placed directly into the user's mouth, or the mouth of apatient, such as for oral medicine or mouthwash, the open nozzle 32 thenmay be placed directly into the mouth and a portion, or all, of thecontents may then be directed into the mouth by squeezing the package.When the desired quantity of the contents of the package has beenexpelled, if some contents remain, package 10 may then be reclosed forfuture use by placing cap 110 over the open nozzle 32.

[0138] As previously mentioned, as here preferably embodied, package 10further includes a cap 110. While cap 110 may be formed separately fromthe other elements of package 10, in the preferred embodiment cap 110 isintegrally formed with and is at least partially detachable from therelatively stiff sheet 12 forming cover 11, as shown in FIGS. 1-3, 9-10,15-18, 22-23 d, 29 a-c, 32-35, 38-40, and 42-47, for example.

[0139] As shown in FIGS. 1-3 and 8-9, cap 110 preferably is located atone corner in cover 11 so as to overhang pouch 22. A cut line 114 allowscap 110 to be easily removed from cover 11. Advantageously, as best seenin FIG. 10, cut line 114 extends only partially along the edge of cover11 so as to provide a tether 130 to maintain cap 110 attached to package10 even after the cap is paced over either the aperture-formingstructure 30 or over the open nozzle 32.

[0140] Cap 110 typically is unthreaded and is dimensioned to fitsmoothly, yet securely, over the necked protrusion 32, which preferablyalso is smooth and unthreaded, both before and after removal of tip 34.Cap 110 has a base 126 which lies flat against the top of cover 11.Tether 130 has several advantages. First, it has been discovered thatthe tether 130 acts as a spring pressing the cap against the sidewall ofthe necked protrusion 32, thereby assisting to hold cap 110 in placewhen it is placed over the necked protrusion 32. Additionally, tether130 provides the added benefit of preventing the cap 110 from becominglost and allows the user to grip the tether 130 to assist in removal ofthe cap 130 from the aperture-forming structure 30 or from open nozzle32.

[0141] Cap 110 of the present invention can be designed in severaldifferent embodiments. For example, in the embodiment shown in FIGS. 10and 11, the cap can be formed from a hollow punch member 120 that forcesthe material into a hollow female member 122 with a central protrusion124 to form a cap with a central plug 126.

[0142] An alternative to the embodiment shown in FIGS. 1-4 is shown inFIGS. 2a and 3 a. As shown, the container 10 a has generally the sameconfiguration as container 10 depicted in FIGS. 1-3 is made of the samematerials. Specifically, pouch 22 a is formed between a flexible sheet18 a and the very thin skin like sheet 12 a, 14 a, in which a flowablesubstance is contained. Unlike the previous embodiment, theaperture-forming protrusion structure 30 a is formed on the underside ofthe flat sheet 18. Similarly, the cap 110 a is formed on the undersideof the sheet 18. With such an arrangement, not only are the neck and tipprotrusions 32 a, 34 a of the protrusion structure 30 a protected fromaccidental rupture, but also the container 10 a is provided with a lowcost flexible cover. In order for the protrusion structure 30 a to be influid communication with the contents of the pouch 22 a, the pouch 22 ais provided with a channel 11 b which communicates with the protrusionstructure.

[0143] It will be understood that the aperture-forming protrusionstructure 30 may be made by a variety of methods and apparatus. Inaccordance with the present invention, however, as preferably embodied,a web of thermoformable material to be formed into cover 11 is firstheated to a sufficient forming temperature. The web is then formed intothe hollow cylindrical protrusion 32 with a closed end. The closed endportion of the cylinder 32 is then further deformed in its centralsection to create the tip 34. At the moment tip 34 is completely formed,the intersection of the base of tip 34 and cylinder 32 is compressed,reducing its thickness, to thereby create a fault line extending aboutthe periphery of the base of tip 34.

[0144] Also in accordance with the present invention, as here preferablyembodied, aperture-forming protrusion 30 is formed by means of aself-centering and self-aligning male and female punch and dieapparatus, indicated generally at 40, as shown in FIGS. 4-7.

[0145] Apparatus 40 includes feed rollers 42 or other means to advancethe web or film “F” of thermoformable material into a heating station 44where a heater block 46 advances against the film to press the sheetagainst a stationary heater block 48, which is temperature controlled bya thermocouple 50 and supplied with necessary power at connection 51. Anair cylinder 52 provides the driving force to move the heater block 46by means of shaft 54. The heater block 46 includes two heaters energizedby an appropriate power source 58.

[0146] A two-stage punch member 60 includes a first male punch 62 formedas a generally cylindrical hollow punch having a substantially flat endsurface 64 at its operative end. When the first punch member isadvanced, the end surface 64 engages and deforms the heated sheet ofthermoformable, preferably plastic, material F, compressing the plasticagainst a similarly shaped, oppositely mounted, generally cylindricalhollow anvil member 66 movable in a bore 68 of a support 70. The anvil66 has an end face 71. The first punch 62 has a clearance fit with thebore 68 so it can be moved therein to confront the end face of the anvil66. Anvil 66 has an aperture bore 67 formed as part of its hollowportion.

[0147] Anvil 66 is part of a spring-loaded rocker member 72, preferablysupported by a ball-shaped member 74, or other similarly shaped curvedrocker device, in a larger base opening 75 so as to be both resilientand self-centering and self-aligning with punch member 60. Althoughrocker 74 is preferably curved or ball-shaped, a relatively flat surfacein spring-mounted engagement with the base of adjustable mechanism 89also serves to self-center the aperture opening 67 of anvil member 66with respect to frusto-conical surface 84 and bevelled surface 83 ofsecond punch 80, more fully described hereinafter. The peripheral edgeor rim of aperture 67 in anvil 66 is smaller than the bore of punch 62to create an internal shoulder 76 when the opposing substantially flatend surfaces 64, 71 of the hollow cylindrical punch member 62 and theanvil member 66 are brought together. The anvil and first punch arepreferably made of hardened steel.

[0148] In use, at the end of the first stage of the formation of theaperture-forming protrusion 30, shown in FIG. 5, the plastic web F isformed into a projecting, closed end, hollow generally cylindricaldrum-like shape, with the plastic web stretched across the end of thefirst generally cylindrical hollow punch, and clamped between theopposed facing end surfaces 64, 71 of the punch and anvil members.

[0149] A second punch member 80 is mounted for travel within a hollowbore 81 and beyond the end face 64 of the first punch member 62. Thesecond punch member 80 includes a shaft 82 whose operative end surfaceincludes a shallow bevel 83, advantageously on the order of 450,terminating into a conically-shaped portion 84 with a flat end face 85forming a frusto-conically shaped tip, indicated generally at 86. Thesecond punch member and its bevel 83 advances into controlled engagementwith the internal peripheral edge of the shoulder 76 formed at theopposed end surfaces 64, 71 of the first punch 62 and anvil 66.

[0150] In one aspect of the present invention, as preferably embodied,the second punch member 80 can be constructed in multiple parts. Forexample, each of the frusto-conical and beveled portions 84, 83 may beformed separately and removably attached to the leading end surface ofthe shaft 82, such as by threaded connections. Alternatively, shaft 82and tip portions 83, 84 may be formed as an integral unit. The secondpunch member is driven by air cylinder 87.

[0151] It will be understood from the foregoing that the full length ofthe frusto-conical end 86 of punch 80 continues to travel past theformed internal shoulder 76 and into the anvil aperture 67 until suchtime as bevel surface 83 is brought into accurately controlledcooperating engagement with the internal peripheral edge of the internalshoulder 76 formed by the opposed end surfaces 64, 71 of the first punch62 and the anvil 66. Advancement of punch surface 83 against shoulder 76is accurately controlled by micrometer punch adjustment mechanism 88 andanvil adjustable stop mechanism 89.

[0152] The still-heated closed end of the initially formed hollowcylinder 32, i.e., the first drum-like protrusion of theaperture-forming structure 30 is, in a second stage, further formed intoa substantially cylindrical or frusto-conically shaped tip 34, i.e., thesecond protrusion of the aperture-forming structure 30, by the advancingsecond punch member until the shallow bevelled surface 83 of punch 80engages the plastic sheet. At that time, the second punch surface 83controllably compresses, cools and sets the plastic web F against theinternal peripherally extending edge formed at shoulder 76 of the anvilto reduce the thickness, and thereby weaken, the wall of the plastic atthe locus of the peripheral edge so as to form a narrow, peripherallyextending indentation 100, known as a rupture or fault line, at the baseof tip protrusion 34. It will be seen that fault line 100 permits thetip protrusion 34 to be readily broken away by means of only lightlateral pressure to thereby form a nozzle-like outlet opening at neckprotrusion 32.

[0153] It should be noted that changes in the dimensions of the beveledend 86 and the anvil 66 are within the scope of the present invention.For example, it is often desirable to produce a fine stream of thecontents of a container, such as motor oil. Consequently, the openingformed by the base of the tip protrusion 34 must be relatively small,such as shown in FIG. 8a. To form such a aperture-forming protrusionstructure 30, the end 86 is elongated, and the beveled surface 83 ispositioned closer to the distal end 85. Furthermore, the anvil 66 isprovided with a relatively narrow opening. Consequently, as shown inFIG. 7a, the fault line 100 and the breakaway tip 34 a are smaller.Alternatively, the entire punch 82 and, therefore, protrusion structure30 is made narrower.

[0154] In other applications, where the contents of a container arelarge particles, such as cat food, the opening must be relatively large,such as shown in FIG. 7b. To achieve a larger opening, the entire punch82 and, therefore, protrusion structure 30 are made wider.Alternatively, the fault line 100 and the break away tip 34 are madelarger.

[0155] In an alternate embodiment illustrated in FIGS. 12 and 13, asingle punch 90 with a truncated end 92 can be used. The single punch 90includes a bevelled surface 94 which engages the film or web F ofthermoplastic material to form the generally frusto-conical hollow tipprotrusion 34. As here embodied, thermoplastic web F is first clampedbetween shoulder plate 96 and face 97 of an outer punch member similarto punch 62. Thereafter, punch 90 advances, whereupon end 94 forms web Finto frusto-conical tip 34, as shown as FIG. 13. As alternativelyembodied, however, as best seen in FIG. 12, upon completion of theformation of tip 34, the peripheral edge 76 a of anvil member 70 engagesand compresses the outer surface of the frusto-conical wall of tip 34 tocreate a peripherally extending fault line 100 a along the projectingsurface of tip 34 between its base and apex.

[0156] In yet another alternative embodiment illustrated in FIGS. 12aand 13 a, a single punch 91 with a beveled, truncated end 93 can be usedto form the generally frusto-conical hollow tip protrusion 31. Thesingle punch 91 engages the film or web F of thermoplastic material withthe beveled surface 93. As with the embodiment shown in FIGS. 13 and 14,the thermoplastic web F is first clamped between stop plate 95 and clampmeans 98 of an outer punch member. Thereafter, punch 91 advances,whereupon end 93 forms web F into the frusto-conical tip 31. As bestshown in FIG. 13a, contact of the peripheral edge 77 of angle member 71compresses the outer surface of the frusto-conical tip 31 to create aperipherally extending fault line 10 b. In contrast to the embodimentshown in FIGS. 12 and 13, the stop plate 95 is situated adjacent theshaft of the punch 91, below the beveled, truncated end 93.Consequently, the thermoplastic web F is formed around the beveled end93 as well as the right cylindrical shaft 91 a. As can best be seen inFIG. 13a, the resulting frusto-conical tip 31 has a breakaway tip 35, apermanent projection 33, and a bright cylindrical section 33 a. Theright cylindrical section 33 a is provided so a cap may be securelyengaged with the tip 31.

[0157] In an alternative embodiment illustrated in FIG. 12b, a singlepunch 91B has a spherical tip 93A. The spherical tip 93A engages thethermoplastic web F to form a hollow mound protrusion. As embodied, thethermoplastic web F is first clamp beneath a stop plate 95A. Thereafter,punch 91B advances, whereupon the spherical end 93A forms web F into ahollow mound. Furthermore, the punch 91B is advanced forwards anvil 71Auntil the outer surface of the web F engages the peripheral edge 77A ofanvil member 71A, thereby creating a fault line that extends around thetip of the mound structures. It has been found that the spherical tip93A allows for self alignment of the punch 91B as the web F engages theperipheral edge 77A of the anvil 71A.

[0158] Referring now more particularly to FIGS. 15-18 of theaccompanying drawings, there is illustrated an alternate embodiment ofthe dispenser package of the present invention, indicated generally byreference manual 200. As here embodied, cover 211 includes a lateralextension 211 a which extends beyond one end of the container pouch 222and both the aperture-forming structure 230 and reclosure cap member 240are formed in cover extension 211 a. A shallow channel member 250communicates aperture-forming structure 230 with the contents of pouch222. Further alternatively, as shown in FIG. 17, lateral extension 211 aof cover 211 is formed on an angle with respect to cover 11 so as toslope toward the pouch side of cover 11.

[0159] It has been found that the embodiments of FIG. 14-17 areadvantageous in that they facilitate dispensing the contents of thepackage onto a surface, such as butter or cream cheese onto a slice ofbread or toothpaste onto a toothbrush.

[0160] Referring now more particularly to FIGS. 18-20, there are shownseveral other alternative embodiments of the cap member of the presentinvention. Thus, as shown at FIG. 18, the top of resealing cap 110 mayinclude bristles or nubs to function as a brush member; as shown in FIG.19, the top of cap 110 may have a flattened surface 270 capable offunctioning as a spreading tool; as shown in FIGS. 20a-d, cap 110 may beopen-ended and have a shaped edge configuration, such as shown at 280,281, 282, 283, respectively, so that the contents of the package may beexpelled in a shaped stream.

[0161] With reference to FIGS. 21a-b and 22 a-c, an alternate embodimentof the present invention will now be shown and described. In accordancewith this alternate embodiment, an independent thermoformed unit is usedto create an outlet aperture in a container. The independentthermoformed unit may take the form of a reclosable outlet formingstructure 300. The reclosable outlet forming structure 300 may generallycomprise a cap 310, a tether 320, a base 330, and a breakaway outlet tip340. Cap 310 may be connected to base 330 via tether 320. Score 325facilitates separation of the cap 310 from structure 300. The reclosableoutlet forming structure 300 may have a pre-applied adhesive or sealantin the area surrounding the base 330 to facilitate application of thestructure 300 to a container, such as milk container 302. As such, thestructure 300 may be sealably or adhesively attached to any surface of acontainer requiring the subject outlet. In particular, the structure 300may be sealed or adhered to the container in an area surrounding a holein the container, but not in the area of the cap 310 or tether 320 whichmust be free of the container's surface. It is to be understood thatreclosable outlet forming structure 300 may be attached to containers,such as milk carton 302, prior to filling. As such, the structure 302may be applied to a container when it is still a flat blank.

[0162] With reference to FIGS. 22a-d, use of the reclosable outletforming structure 300 will now be shown and described. With reference toFIG. 22a, prior to shipping of the container 302, the cap 310 may beplaced over the outlet forming structure base 330 prior to removal ofthe breakaway tip 340 so as to assure that the breakaway tip 340 doesnot accidentally break and the contents of container 302 do not escapewhile the container 302 is in transit. With reference to FIG. 23b, thecap 310 is removed from base 330 to provide access to breakaway tip 340.The container at this point is ready for opening. With reference to FIG.23c, the breakaway tip 340 is then removed to create an opening 350.Opening 350 leads to a hole (not shown) in container 302 to allowpouring the contents of container 302 therethrough. With reference toFIG. 23a, the reclosable outlet forming structure 300 may be resealed bysimply placing the cap 310 over base 330.

[0163] In one embodiment of the present invention, base 330 and tip 340are cylindrical or substantially cylindrical, although it is to beunderstood that other shapes may be used. In this embodiment, theopening 350 is made of PET-PVC-BAREX. It is to be understood, however,that other materials in accordance with the present invention may beused.

[0164] As can be seen in FIG. 22d, the cylindrical outlet 330 andopening 350 act a nozzle direct the flow of the contents of thecontainer 302 into a control stream.

[0165] With reference to FIGS. 23-26, a low profile breakaway tip andcap in accordance with another embodiment of the present invention isshown. In general, lowering the height of a breakaway tip 360 will lowerthe possibility that the tip 360 may be accidentally opened duringtransit or by handling. Lowering the height of the breakaway tip makesit more difficult, however, to grasp and remove the breakaway tip. Thisdifficulty is alleviated by creating undercuts or indents 370 in thesidewall of the breakaway tip 360. These undercuts or indents 370 allowsa user's finger to hook and break away the tip 360 in a single motion.FIG. 25 is a perspective view of the low profile breakaway tip with theremoved breakaway tip shown in phantom. With continuing reference toFIGS. 23-25, the undercuts or indents 370 are preferably arranged inopposed positions to facilitate ease of use and manufacture. It is to beunderstood that the number and location of the undercuts/indents 370 maybe varied. Once the breakaway tip 360 is removed from base 380, a cap394 may be used to reclose the opening (not shown) exposed by theremoval of tip 360 in base 390. Base indents 392 in base 380 are shapedand dimensioned to receive opposed inward protrusions 396 of cap 394.These protrusions 394 snap into indents 392, thereby securing cap 390 tobase 380. A tether (not shown) may also be used to attach cap 390 tobase 380.

[0166] As shown in FIGS. 23a and 24 a, the base 390 a may have generallytriangular cross-sectional area. Such a cross-sectional area, may aid inthe dispensing of various materials. Furthermore, the relatively largebottom of the base 390 a helps avoid accidental toppling of a container.

[0167] It is also to be understood that this embodiment of the presentinvention may be used in a wide variety of applications, includingdispensers for creamers, unit dose medications, salad dressings, beautyaids, dental products, condiments, candy confections, syrups, granularproducts, etc. It is also to be understood that this embodiment of thepresent invention may be manufactured by utilizing a male punch memberin conjunction with a self-centering and receding female anvil system,as previously shown and described.

[0168] Although the use of a tether limits the rotation of a cap pressedonto a base formation, a twist-lock or twist-threading arrangement mayalso be used to secure the cap to the base. With reference to FIG. 28,such an embodiment of the present invention which utilizes a twist-lockor twist-threading arrangement 400 to secure the cap 410 to the baseformation 420 is shown. In this arrangement, cap 410 has an innerprotrusion 415 which engages cam surface 430 of base 420. Upon rotationof cap 410 with respect to base 420, inner protrusion 415 engages camsurface 430 to create a twist-lock or twist-thread arrangement. It is tobe understood that a tether (not shown) may also be used in such anarrangement. Base 420 may also have a breakaway tip 425 attachedthereto.

[0169] As an alternative to the breakaway tip and tethered caparrangement, the present invention also includes a tethered plug/punchand scored surface arrangement as shown in FIGS. 28a-c, 29 a-d and 30a-d. FIGS. 28a and 28 b are perspective views of such an embodiment ofthe present invention in which a tethered plug is used to open and closea pre-scored surface. In this arrangement 450, a plug 460 is used toopen a pre-scored surface 470 of outlet 480. In this embodiment, thescore is in the form of an interrupted circle, although it is to beunderstood that other types of scored surfaces, such as those shown inFIGS. 29a-d, may also be used. FIGS. 28b and 28 c depict a flap 485which is created when plug 460 is used to penetrate the scored surface470. A tether 490 may also be created through the use of a score 495 inarrangement 450. Plug 460, which may be connected to arrangement 450 viathis tether 490, may also be used as a cork to close the outlet hole. Assuch, plug 460 may be used both as a plug and as an opening tool tocreate and/or plug an aperture in the pre-scored surface. In thisembodiment, plug 460 has a conical shape, although it is to beunderstood that other shapes may be used. Similarly, as shown in FIGS.28a and 29 a-d, the score may have a partially circular shape, aV-shape, an X-shape, a star shape, or box shape, although it is to beunderstood that other patterns may also be utilized. Depending on theshape of the scored surface, the flap created by the penetration of plug460 will differ. For example, the penetration of scored V-shaped surface490 will create a flap 491; the penetration of scored X-shaped surface492 will create a flap 493; the penetration of scored star-shapedsurface 494 will create a flap 495; and the penetration of a scoredsurface 496 will create a rectangular-shaped flap 497.

[0170] An alternative embodiment of the present invention will now bediscussed with reference to FIGS. 31-36. In accordance with thisalternative embodiment, a container 500 is provided with a reclosableoutlet forming structure 510. More specifically, the outlet formerstructure 510 comprises a curvilinear dome or mound 530 and a dualpurpose punch/plug 520. As will be apparent to one of skill in the art,the container 500 includes a hole, not shown, over which the mound 530is secured. Because the punch/plug 520 must be lifted and inverted forinsertion into the scored area 532, it must not be sealed to thecontainer 500. On the other hand, the mound 530 portion of the outletforming structure 510 must be securely adhered over the hole in thecontainer 500.

[0171] As can best be seen in FIG. 34, the outlet forming structure 510comprises a layer of foil 534 laminated to the plastic forming theoutlet forming structure 510. The portion of the foil 534 underneath themound 530 should be unsupported other than the adhesive used to secureit to the mound 530. It should also be noted that the foil 534 issecured to the container 500, about the hole in the container 500, sothat the contents do not leak out beneath the outlet forming structure510. The foil laminated adhesive should be one that gives adequateadhesion but sets up with minimal tensile strength of its own. Inalternative embodiments, the adhesive may approach being brittle.

[0172] The mound 530 further includes a fault line pattern or scoredpattern 532. The fault lines 532 may take on any number of patterns,such as those shown in FIGS. 29a-d. As shown in FIGS. 35 and 36, thefoil 534 is laminated to the entire surface of the mound 530 andpreferably, is not scored. In an alternative embodiment, the adhesivemay be omitted from the fault line pattern 532.

[0173] The punch/plug 520 is secured to the outlet forming structure 510via a tether 524. The tether 524 is created by a cut 522 through thefoil/plastic laminate. As can best be seen in FIG. 32, the cut 522preferably takes a curvilinear path, following the periphery of theoutlet forming structure 510. Such a cut 522 provides an elongatedtether 524.

[0174] In operation, the punch/plug 520 is firmly pushed into the faultline pattern 532 to rupture the scored mound 530. This operation is bestshown in FIG. 35. Having forced the punch/plug 520 through the scoredarea 532 of the mound 530, an opening for dispensing the contents of thecontainer 500 is formed. The punch/plug 520 is removed from the mound530 so that contents of the container 500 may be dispensed. Because thescored area 532 has been deformed to the shape of the punch/plug 520,the punch/plug 520 may be reinserted into the scored area 532, therebyresealing the container 500.

[0175] In an alternative embodiment, however, the foil layer 534 mayspan the hollow base of the mound 530 by being laminated only to theperiphery of the mound. Of course, in such an embodiment, the punch/plug520 must be long enough to extend past the plane of the foil 534 so thatthe foil 534 may be punctured. By wobbling the punch/plug 520 whileinserted into the mound 530, the opening in the foil is enlarged.

[0176] It should be noted that the mound 530 strengthens the outletforming structure 510. Furthermore, the shape of the mound 530 providesa nozzle function, directing the contents of the container 500 in aneven stream. Depending upon the contents of the container 500, thedimensions and shape of the mound 530 may be altered to provide thedesired flow.

[0177] The outlet forming structure 510 of FIGS. 31-36 are preferablymanufactured with a punch similar to that described with reference toFIG. 12b. Of course, the tip of the punch need not be spherical, butrather may be elliptical, parabolic, or any curvilinear shape.Furthermore, it is preferred that the foil and plastic be laminated intoa single web prior to the formation of the mound be the punch. Thus, thedimensions of the mound, as defined by the shape of the punch tip, willbe limited only be the physical properties of the materials used.

[0178] In an alternative embodiment, which will now be described withreference to FIGS. 37-38, a reclosable outlet forming structure 610according to the present invention is utilized with a flexibleplasti-foil pouch 600. In general, the foil pouch 600 is formed byfolding a generally rectangular shaped piece of the foil plasticcombination in half and sealing the three open edges thereof. Areclosable outlet forming structure 610 is mounted on the seamless end605 of the pouch 600. The outlet forming structure 610, which is sealedto the seamless end of the pouch 600 by applying an adhesive around aperiphery of the base 612, covers a hole, not shown, in the pouch 600.

[0179] The outlet forming structure 610 may be of any type previouslydisclosed above, such as those described with reference to FIGS. 1-3,8-9, 13, and 13 a. In a preferred embodiment, as shown in FIGS. 37 and38, the outlet forming structure 610 includes an aperture formingprotrusion 630. More specifically, the aperture forming protrusion 630includes a hollow cylindrical base 632 and a break-away tip 634. A faultline 636 extends around the periphery of the protrusion structure 630,permitting the breakaway tips 634 to be broken away from the base 632 inthe tip 634. More specifically, the fault line 636 is a narrowed, stressconcentrating area.

[0180] The outlet forming structure 610 also includes a cap 620. The cap620 is a hollow tapered member, which has an inside base diameterslightly larger than the outside diameter of the base 632 of theprotrusion structure 630. The cap 620 is secured to the outlet formingstructure 610 via a tether 624. The tether 624 is formed by a cut 622through the lower surface 612 of the outlet forming structure 610. Ascan best be seen in FIG. 39, the curvilinear cut 622 separates the cap620 from the protrusion structure 630 and follows the periphery of thebase 612. By having such a pattern, the cut 622 is relatively long and,consequently, produces a relatively long tether 624. Due to the longtether 624 and the fact that the portion of the base 612 that supportsthe cap 620 is not fastened to the pouch 600, the cap 620 may be raisedand securely placed over the outlet forming structure 630.

[0181] In operation, a user applies sidewise finger pressure to theprotrusion tip 634, thereby causing it to break away from the protrusionbase 632 along a fault line 636. Because the protrusion structure 630 issubstantially hollow, an aperture, not shown, is created. Furthermore,because the protrusion member 630 has been affixed to the pouch 600 overa hole in the pouch, not shown, the contents of the pouch 600 may bedispensed via the now opened protrusion neck 632. The cap 620 is placedover the base 632 during shipping, so that accidental rupturing of thefault line 636 is prevented. Furthermore, cap 620 is placed over thebase 632 to reclose the package 600 when only a portion of the contentsof the package 600 has been dispensed.

[0182] In an alternative embodiment, shown in FIG. 39, the same outletforming structure 610 is secured to the side of pouch 640. In thisembodiment, the pouch 640 is formed from two generally rectangularsheets of foil plastic laminate which are sealed together around allfour sides of each sheet. As with the previous embodiment, theprotrusion structure 630 is affixed to the pouch 640 over a hole, notshown, so the protrusion neck 632 is in fluid communication with thecontents of the pouch 640.

[0183] An alternative embodiment of the present invention employing anoutlet forming structure 610 a disposed on a foil pouch 640 a will nowbe described with reference to FIGS. 37a, 38 a, and 39 a. Brieflydescribed, the outlet forming structure 610 a is substantial the same asthe outlet forming structure described with reference to FIGS. 37-39.Specifically, the outlet forming structure 610 a includes both a cap 620a and a protrusion member 630 a. As best seen in FIG. 39a, the foilpouch 640 a includes a lap seam on the side opposite the outlet formingstructure 610 a.

[0184] An alternative embodiment of the present invention will now bedescribed with reference to FIG. 40. A tethered punch/plug and basemember with a star shaped fault pattern manufactured as a unit 700 isshown. A tether 730 is connected to the base 710 at a proximal endthereof, a ring structure 740 connected to a distal end thereof, and atapered punch/plug 760. The punch/plug 760 is manufactured separatelyfrom the other components.

[0185] As shown, the ring structure 740 defines an opening 750. Theopening 750 is larger than the tip 762 of the punch/plug 760 yet smallerthan the base 764 of the punch/plug 760. Furthermore, the punch/plug 760includes a circumferential indentation 766. The indentation 766 isformed on the punch/plug 760 just below a point where the outsidediameter of the punch/plug 760 becomes larger than the inside diameterof the opening 750.

[0186] Therefore, once the components have been separately manufactured,the punch/plug 760 is snapped into the opening 750. When snapped intothe opening 750, the tapered punch/plug 760 causes the slightly elasticring structure 740 to expand until the ring structure 740 reaches theindentation 766. Upon reaching the indentation 766, the ring structure740 snaps into the indentation 766. Consequently, the punch/plug 760becomes connected to the ring structure 740 and the other components.

[0187] In use, as shown in FIG. 40a, the punch/plug 760 is used topuncture the scored section 722 of the protrusion structure 720. Suchoperation is described in greater detail with reference to FIGS. 28-30d.

[0188] Turning now to FIG. 41, one embodiment for manufacturing areclosable outlet forming structure according to the present inventionis shown. Specifically, a pair of reclosable outlet forming structures870 and 880 are formed from the same piece of thermoplastic web F. Eachreclosable outlet forming structure 870, 880 comprises a protrusionstructure 872, 882 as well as cap 874, 884, respectively. As in thepreviously disclosed embodiments, each cap 874, 884 is connected to thecorresponding protruding structure 870, 880 via a tether 876, 886.

[0189] It is to be understood that the mating, horse-shoe arrangement ofthe outlet forming structures 870, 880 provides several benefits, suchas reclining wasted portions of the web F, and that the manufacturingagreement may be repeated along the length of the web F.

[0190] Turning now to FIGS. 42-44, an alternative embodiment of thepresent invention is shown. Initially, it should be noted that thecontainer 1000 shown is made of similar materials as described abovewith reference to FIG. 1-3.

[0191] The container 1000 comprises a first deformable pouch 1010 and asecond deformable 1020. The two pouches 1010, 1020 are joined by ashallow conduit 1030. The deformable pouches 1010, 1020, as well as thejoining conduit 1030, are sealed by a generally flat sheet 1040 ofthermoformable plastic material. A hollow protrusion 1050 is integrallyformed with the flat sheet of thermoformable plastic 1040. The hollowprotrusion 1050 extends from the flat sheet 1040. The protrusion 1050 isdirectly above and in fluid communication with the conduit 1030. Thecontainer 1000 further includes a punch/cap 1060.

[0192] As can best be seen in FIG. 43, the hollow protrusion 1050 hasscores or fault lines 1055 on the top face thereof. Despite these faultlines 1055, which weaken the protrusion 1050, the container 1000 remainssealed. Further shown in FIG. 46, the punch/cap 1060 is partiallyseparated from the remainder of the container 1000 by cut 1062. The cut1062 which parallels one peripheral edge of the container 1000 creates atether 1064.

[0193] In order to open the container 1000, the punch/cap 1060 ispositioned over the protrusion 1050. The punch/cap 1060, and morespecifically the pointed end 1066 of the punch/cap 1060 is forcedthrough the score or fault lines 1055, thereby opening the hollowprotrusion 1050. When punch/cap 1060 is removed from the hollowprotrusion 1050, an opening, not shown, exists. The opening is formed bythe permanent deformation of the portion of the protrusion member 1050between the fault lines 1055. By inverting the container 1000 and gentlysqueezing either or both of the pouches 1010, 1020 the materialcontained within the pouches is dispensed via the opening in theprotrusion 1050.

[0194] It should be noted that in the preferred embodiment theprotrusion 1050 is placed directly above the conduit 1030. As a result,the contents of the pouches 1010, 1020 can be dispensed in a controlledmanner. Specifically, the shallow conduit 1030 provides resistance tothe flowing contents so that the contents do not spout from the openedprotrusion 1050 uncontrollably, particularly when the protrusion 1050 isinitially punctured.

[0195] As shown in FIG. 44, should less than all of the materialcontained within the pouch 1010, 1020 be dispensed, the container 1000may be reclosed. Specifically, the punch/cap 1060 is inverted bytwisting the tether 1064. Because the punch/cap 1060 is hollow, havingan inside diameter substantially the same as or slightly larger than theoutside diameter of the protrusion 1050, the punch/cap 1060 can besecurely placed on the protrusion 1050.

[0196] With regard to the embodiment of FIGS. 42-44, it will be apparentto one skilled in the art that the invention is not limited by the typeof outlet forming structure utilized. Specifically, any combination ofbreak away tip, scored protrusion member, punch, plug, and cap may beemployed. Furthermore, it should be understood that the particular shapeof the pouches may vary according to the properties of the contents heldtherein.

[0197] An alternative embodiment of the present invention will now bedescribed with reference to FIGS. 45-47. As shown in FIG. 45, an outletforming structure 1070 comprises a cap member 1072 and an apertureforming protrusion 1074. As with the embodiments discussed above, thecap member 1072 is connected to the aperture forming structure 1074 by atether 1076. As can be seen, both the cap member 1072 and the apertureforming structure 1074 are formed in a curvilinear base 1078.

[0198] Because the outlet forming structure 1070 is formed in acurvilinear base 1078, it may be positioned on a container 1080 having asimilar curvilinear surface. As shown in FIGS. 46a-c, one such container1080 is generally spherical and formed in two halves 1082, 1084. The twohalves 1082, 1084 are joined at one point along their circumferences,and are therefore hingeably connected. One half 1084 of the container1080 includes an aperture 1086 formed therein.

[0199] In operation, as shown in FIG. 47, the outlet forming structure1070 is affixed to the container 1080 such that the aperture formingstructure 1074 is in alignment with the aperture 1086 in the container1080. As further depicted in FIG. 47, the cap member 1072, shown in asectional view, may be positioned over the aperture forming structure1074, thereby protecting it and sealing the container 180. It is to beunderstood that the shape of the container 1080 is merely representativeof those that may be employed with the present invention, as the outletforming structure may be formed on a curvilinear base having virtuallyany shape.

[0200] Another alternative embodiment of the present invention will nowbe described with reference to FIGS. 48-51. The container 1090 generallycomprises a rectangular sheet 1091 of thermoformable material. At thecenter of the rectangular sheet 1091 is an aperture forming structure1092, having a base and break away tip as described above with referenceto the prior embodiments. On either side of the aperture formingstructure 1092 are pouches 1098 formed on the underside of the sheet1091 for holding any flowable substance. The pouches 1098 are in fluidcommunication with the aperture forming structure 1092.

[0201] Also formed in the rectangular sheet 1091 of thermoformablematerial is a cap member 1094. The cap member 1094 is preferably formedin one corner of the rectangular sheet 1091 and attached to thecontainer 1090 via a tether 1096. The tether 1096 is formed by a cut1097 extending along the perimeter of the container 1090.

[0202] The container 1090 may be folded generally in half along bendinggrooves 2006 disposed on either side of the aperture forming structure1092. Specifically, the ends of the container 1090 are brought togetheras depicted by arrows “A” in FIG. 49. Once the ends are broughttogether, a female package tie 2000 and a male package tie 2002, both ofwhich are integrally formed in the sheet of thermoformable material1091, are brought into engagement.

[0203] Engagement of the female package tie 2000 and the male packagetie 2002 hold the container 1090 in the configuration as shown in FIGS.50 and 51. In operation, lateral finger pressure on the tip of theaperture forming structure 1092 causes a fault line to rupture, therebyforming an aperture in the aperture forming structure 1092. Thus, thecontents of the container 1090 may be dispensed from the aperture. Asshown in FIG. 51, the cap member 1094 may be placed over the apertureforming structure 1092, thereby preventing accidental rupturing of thefault line or accidental dispensing of the contents after the tip of theaperture forming structure 1092 has been removed.

[0204] Another alternative embodiment of the present invention will nowbe described with reference to FIGS. 52-54. As shown in FIG. 52, anaperture forming structure 2016 according to the present invention maybe positioned on a treated paper board tube 2012, thereby forming asealed container 2010. The aperture forming structure 2016 comprises agenerally hollow frusto-conical portion 2018, a hollow cylindricalportion 2019, and a breakaway tip 2020. Integrally formed with theaperture forming structure 2016 is a cap member 2022 and an associatedtether 2024. As can best be seen in FIG. 54, the tether 2024 is formedby a curvilinear cut which allows the cap member 2022 to be partiallyseparated from the aperture forming structure 2016 so that the capmember 2022 may be positioned over the cylindrical portion 2019 and thebreakaway tip 2020. Because the cap member 2022 has an inside diameterslightly larger than the outside diameter of the cylindrical portion2019, the cap member 2022 fits snugly thereon, thereby sealing thecontainer 2010.

[0205] As with the previously described embodiments, in operation,lateral pressure on the breakaway tip 2020 causes it to separate fromthe rest of the aperture forming structure 2016, thereby forming anaperture into the generally hollow aperture forming structure 2016.Thus, the contents of the container 2010 may be dispensed therefrom.

[0206] It will remain understood by those skilled in the art that thepresent invention in its broader aspects is not limited to theparticular embodiments shown and described herein, and that variationsmay be made without departing from the principles of the invention andwithout sacrificing its chief advantages.

I claim:
 1. An aperture forming means for packages or containerscomprising a break away tip member made of thermo-formed plasticcomprising a hollow protrusion from a surface whose entire intersectionwith said surface comprises a locus of a fault line.
 2. The apertureforming means of claim 1 wherein said hollow protrusion isfrusto-conical.
 3. The aperture forming means of claim 1 wherein saidsurface having said hollow protrusion site atop a covered cylindricalbase member formed and protruding from a thermo-formable plastic film.4. The aperture forming means of claim 1 wherein said hollow protrusionis relatively shallow, said hollow protrusion having at least one sideindent.
 5. The aperture forming means of claim 1 further comprising atleast one additional hollow protrusion adjacent said coveringcylindrical base member.
 6. The aperture forming means of claim 5wherein said at least one additional hollow protrusion is a cap memberfor said hollow protrusion.
 7. The aperture forming means of claim 6wherein said cap member has an inward protrusion and said cylindricalbase member has a related cap member, such that when twisted, said capmember is compressed into said cylindrical base member.
 8. The apertureforming means of claim 6 wherein said cap member is tapered.
 9. Theaperture forming means of claim 3 further comprising at least oneadditional hollow protrusion so shaped as to function as a cap member tofit snugly about said covered cylindrical base member and over saidhollow protrusion.
 10. The aperture forming means of claim 5 whereinsaid at least one additional hollow protrusion has an open end and aclosed end, said open end being a cap member and said closed end being apunch/plug.
 11. The aperture forming means of claim 5 wherein said oneadditional hollow protrusion is so shaped as to function as a cap memberwith a centrally formed punch/plug extending along a longitudinal axiswithin said at least one additional hollow protrusion.
 12. The apertureforming means of claim 5 wherein said at least one additional hollowprotrusion is so shaped as to function as a tool member atop of a cap.13. The aperture forming means of claim 5 further comprising a portionof a thin gauge material adjacent to and between said protrusion andsaid at least one additional hollow protrusion so cut as to form atether therebetween.
 14. An aperture forming means comprising aprotrusion which is cylindrical, said protrusion being formed fromthermo-formable plastic with one integral covered end, said covered endhaving a fault line pattern which pattern, when pressed into a spacedefined by said protrusion, ruptures in a predetermined pattern tocreate a predetermined aperture.
 15. The aperture forming means of claim14 wherein said fault line pattern creates a circular aperture.
 16. Theaperture forming means of claim 14 wherein said fault line patterncreates a polygonal aperture.
 17. The aperture forming means of claim 14wherein said protrusion is a hollow mound.
 18. An aperture forming meanscomprising a thermo-formed member having a hollow frusto-conicalprotrusion from a surface atop a hollow cylindrical based member whereinan intersection of said hollow frusto-conical protrusion with saidsurface atop said hollow cylindrical based member comprises a locus of afault line to create a break away tip with an adjacent tethered capmember, said break away tip and said tethered cap member being securelysealingly attached to a container wherein said cylindrical based memberis located directly over a hole in said container.
 19. Apparatus to forma hollow protrusion from heated thermoplastic film where said hollowprotrusion intersects said heated thermoplastic film, said entireintersection comprising the locus of a fault line, including: (a) punchmeans comprising a tip portion with a shallow frusto-conical formationat the base of said tip portion; and (b) a female die having anaccurately bored hole in a flat die block, said hole of slightly largerdiameter than the base of said tip portion of said punch means, sodimensioned that when said punch means is introduced into said femaledie when forming said heated thermoplastic film the base rim, ifadvanced to contact said frusto-conical formation, the locus of suchcontact would be a circle located approximately centrally between thelarger base circle and the smaller end circle of the frusto-conicalformation.
 20. Apparatus to form a hollow protrusion from heatedthermoplastic film where said hollow protrusion intersects said heatedthermoplastic film, said entire intersection comprising the locus of afault line, including: (a) a supply of thermoplastic film; (b) means tocontrollably heat a section of said film; (c) means to transfer saidheated film section to the locus of the center of said apparatus; (d)punch means comprising a tip portion with a shallow frusto-conicalformation at the base of said tip portion extending from a shaft; (e)resiliently mounted film clamp means with a central hole through whichsaid punch member may pass; (f) guided mounting plate means to whichsaid clamp means and punch means are concentrically mounted with saidpunch means located beneath the clamp face of said resilient clamp meansand concentric with its central hole to reciprocatingly and controllablyadvance and retract said resiliently mounted film clamp means and punchmeans with respect to a female die; and (g) a female die having anaccurately bored hole in a stationary flat die-plate located in accuratealignment with said punch means, said bore diameter so dimensioned thatwhen the punch means is advanced said bore rim would be in accuratealignment with said shallow frusto-conical formation at the base of thepunch tip and if advanced to contact said shallow frusto-conicalformation the locus of said contact would be a circle locatedapproximately centrally between the larger base circle and the smallerend circle of said shallow frusto-conical formation.
 21. Apparatus toform a hollow protrusion from heated thermoplastic film where saidhollow protrusion intersects said heated thermoplastic film, said entireintersection comprising the locus of a fault line, which hollowprotrusion extends from a closed hollow essentially cylindrical baseportion, including: (a) punch means comprising a tip portion with ashallow frusto-conical formation at the base of said tip portion; (b) aspring loaded self-centering retractable female die member configured tomate with said punch means, and (c) a spring loaded film clamp meanswith a central hole through which said punch member may pass,cylindrical means extending from said central hole whose outer diameterfunctions as a punch means to form the inside diameter of the closedhollow essentially cylindrical base portion and whose height forms theinner height of said protrusion when cooperating with said female diemember.
 22. The apparatus of claim 21 where the female die memberincludes a ball ended base, wherein movement of said female die memberis limited in one direction by the ball ended base contacting anadjustable stop means, a spring member seated on said adjustable stopmeans compressor against a flange located on the female die memberpressing said flange against a fixed stop means to encapture the femaledie member.
 23. The apparatus of claim 21 including additional means toform an adjacent cap member protrusion and tether from said heatedsection of thermoplastic film, said additional means comprising: (a)secondary punch means comprising a tip so shaped as to create a hollowthermoplastic cap member with tapered walls to firmly engage said hollowessentially cylindrical base portion when used in conjunction with acooperating female die member; (b) a female die member comprising a holein a plate of such dimension as to allow punch member and heatedthermoplastic film to pass through it with low resistance; (c) saidpunch and die means located adjacent to said apparatus to form saidhollow cap member at such distance as to permit a cutting means tocreate a tether between said cap means and said hollow base portion; and(d) cutting means to create a tether.
 24. Apparatus to form a hollowtapered protrusion from heated thermoplastic film where a fault line maybe formed encircling an outer surface of said protrusion at variouspredetermined heights including: (a) punch means comprising a taperedtip extending from a round shaft member; (b) a film stop plate with ahole so sized as to permit said punch means and said heatedthermoplastic film being formed to pass through to reach a female diemeans; (c) female die means comprising a bored die block, said bore tobe of such diameter as to locate the fault line on the outer surface ofthe tapered member protrusion at a predetermined location whencooperating with said punch member.